US7216428B2 - Method for turbine element repairing - Google Patents

Method for turbine element repairing Download PDF

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Publication number
US7216428B2
US7216428B2 US10/635,694 US63569403A US7216428B2 US 7216428 B2 US7216428 B2 US 7216428B2 US 63569403 A US63569403 A US 63569403A US 7216428 B2 US7216428 B2 US 7216428B2
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United States
Prior art keywords
airfoil
component
based material
damage site
physically depositing
Prior art date
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US10/635,694
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English (en)
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US20040172825A1 (en
Inventor
Robert L. Memmen
James W. Neal
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RTX Corp
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United Technologies Corp
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Publication date
Priority claimed from US10/377,954 external-priority patent/US8122600B2/en
Application filed by United Technologies Corp filed Critical United Technologies Corp
Assigned to UNITED TECHNOLOGIES CORPORATION reassignment UNITED TECHNOLOGIES CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MEMMEN, ROBERT L., NEAL, JAMES W.
Priority to US10/635,694 priority Critical patent/US7216428B2/en
Priority to US10/734,696 priority patent/US7509734B2/en
Priority to UA20040705668A priority patent/UA79258C2/uk
Priority to UA20040705667A priority patent/UA81401C2/xx
Priority to KR1020040054709A priority patent/KR100704806B1/ko
Priority to KR1020040054708A priority patent/KR100704805B1/ko
Priority to SG200404327A priority patent/SG108982A1/en
Priority to SG200404374A priority patent/SG109003A1/en
Priority to DE602004016922T priority patent/DE602004016922D1/de
Priority to JP2004229402A priority patent/JP4021883B2/ja
Priority to AT04254725T priority patent/ATE410530T1/de
Priority to JP2004229403A priority patent/JP4160027B2/ja
Priority to EP04254725A priority patent/EP1505168B1/en
Priority to EP20040254727 priority patent/EP1505169B1/en
Priority to CNA2004100560387A priority patent/CN1584104A/zh
Priority to CNA2004100560279A priority patent/CN1584103A/zh
Publication of US20040172825A1 publication Critical patent/US20040172825A1/en
Publication of US7216428B2 publication Critical patent/US7216428B2/en
Application granted granted Critical
Priority to US11/930,564 priority patent/US20080057254A1/en
Priority to US12/756,624 priority patent/US20100196684A1/en
Assigned to RAYTHEON TECHNOLOGIES CORPORATION reassignment RAYTHEON TECHNOLOGIES CORPORATION CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: UNITED TECHNOLOGIES CORPORATION
Assigned to RAYTHEON TECHNOLOGIES CORPORATION reassignment RAYTHEON TECHNOLOGIES CORPORATION CORRECTIVE ASSIGNMENT TO CORRECT THE AND REMOVE PATENT APPLICATION NUMBER 11886281 AND ADD PATENT APPLICATION NUMBER 14846874. TO CORRECT THE RECEIVING PARTY ADDRESS PREVIOUSLY RECORDED AT REEL: 054062 FRAME: 0001. ASSIGNOR(S) HEREBY CONFIRMS THE CHANGE OF ADDRESS. Assignors: UNITED TECHNOLOGIES CORPORATION
Assigned to RTX CORPORATION reassignment RTX CORPORATION CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: RAYTHEON TECHNOLOGIES CORPORATION
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/58—After-treatment
    • C23C14/5873—Removal of material
    • C23C14/588—Removal of material by mechanical treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P6/00—Restoring or reconditioning objects
    • B23P6/002—Repairing turbine components, e.g. moving or stationary blades, rotors
    • B23P6/007—Repairing turbine components, e.g. moving or stationary blades, rotors using only additive methods, e.g. build-up welding
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/02—Pretreatment of the material to be coated
    • C23C14/028—Physical treatment to alter the texture of the substrate surface, e.g. grinding, polishing
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/04—Coating on selected surface areas, e.g. using masks
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C23C14/14—Metallic material, boron or silicon
    • C23C14/16—Metallic material, boron or silicon on metallic substrates or on substrates of boron or silicon
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/005—Repairing methods or devices
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/30—Fixing blades to rotors; Blade roots ; Blade spacers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/30—Manufacture with deposition of material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/80—Repairing, retrofitting or upgrading methods
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/49318—Repairing or disassembling
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49718—Repairing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49718—Repairing
    • Y10T29/49732—Repairing by attaching repair preform, e.g., remaking, restoring, or patching
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49718—Repairing
    • Y10T29/49732—Repairing by attaching repair preform, e.g., remaking, restoring, or patching
    • Y10T29/49734—Repairing by attaching repair preform, e.g., remaking, restoring, or patching and removing damaged material
    • Y10T29/49737—Metallurgically attaching preform
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49718—Repairing
    • Y10T29/49732—Repairing by attaching repair preform, e.g., remaking, restoring, or patching
    • Y10T29/49742—Metallurgically attaching preform
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49718—Repairing
    • Y10T29/49746—Repairing by applying fluent material, e.g., coating, casting

Definitions

  • the invention relates to the restoration of turbine elements. More particularly, the invention relates to the restoration of worn or damaged gas turbine engine fan blades and compressor blades and vanes.
  • the components of gas turbine engines are subject to wear and damage. Even moderate wear and damage of certain components may interfere with proper operation of the engine. Particular areas of concern involve the airfoils of various blades and vanes. Wear and damage may interfere with their aerodynamic efficiency, produce dynamic force imbalances, and even structurally compromise the worn/damaged parts in more extreme cases. A limited reconditioning is commonly practiced for slightly worn or damaged airfoils wherein additional material is removed yet further below the wear/damage to provide the airfoil with a relatively efficient and clean sectional profile albeit smaller than the original or prior profile.
  • U.S. Pat. No. 4,822,248 discloses use of a plasma torch to deposit nickel- or cobalt-based superalloy material.
  • U.S. Pat. No. 5,732,467 identifies the use of high velocity oxy-fuel (HVOF) and low pressure plasma spray (LPPS) techniques for repairing cracks in such turbine elements.
  • HVOF high velocity oxy-fuel
  • LPPS low pressure plasma spray
  • U.S. Pat. No. 5,783,318 also identifies LPPS techniques in addition to laser welding and plasma transferred arc welding.
  • U.S. Pat. No. 6,049,978 identifies further use of HVOF techniques. Such techniques have offered a limited ability to build up replacement material to restore an original or near original cross-section. However, the structural properties of the replacement material may be substantially limited relative to those of the base material.
  • one aspect of the invention involves a method for restoring a Ti alloy component which has lost first material from a damage site. Additional material may be removed at least partially from the damage site to create a base surface. A Ti-based material is physically deposited atop the base surface at least partially in place of the first material and the additional material.
  • the Ti-based material may be Ti-6Al-4V, Ti-6Al-2Sn-4Zr-2Mo or Ti-8Al-1V-1Mo and may be essentially identical to the base Ti alloy of the component.
  • the removing of additional material may be, in major part, from undamaged portions of the component.
  • the deposited material may, in major part, essentially, or totally replace the first and additional material.
  • the component may be a blade having a root and an airfoil and the damage site may be along a leading edge of the airfoil inboard of a midspan shroud of the airfoil.
  • the damage site may be inboard of the midspan shroud by an exemplary no more than 15% of a span of the airfoil.
  • the damage site may be located between 30% of such span inboard of the midspan shroud and 20% of such span outboard of the midspan shroud. Such inboard and outboard limits may, more narrowly, be 20% and 10%.
  • the first material may be lost to a depth of at least 2.0 mm.
  • the method may further involve applying a backing element to the component protruding adjacent the damage site after the removal so that the deposited metal builds up on the base surface and backing element.
  • the method may further involve at least partially removing the backing element and machining adjacent deposited material and preexisting material of the component to create a second base surface. More of the metal may then be physically deposited atop the second base surface.
  • the depositing may include vapor deposition, electron beam physical vapor deposition, and electron beam flash vapor deposition.
  • FIG. 1 is a view of an airfoil of a fan of a gas turbine engine.
  • FIG. 2 is a tip-inward view of the airfoil of FIG. 1 .
  • FIG. 3 is a partial sectional view of the airfoil of FIG. 1 upon damage.
  • FIG. 4 is a partial sectional view of the airfoil of FIG. 1 upon wear.
  • FIG. 5 is a partial sectional view of the airfoil of FIG. 1 after machining to remove damaged/worn surfaces.
  • FIG. 6 is a partial sectional view of the airfoil of FIG. 5 after the application of a backing element.
  • FIG. 7 is a partial sectional view of the airfoil of FIG. 6 after deposition of initial material to rebuild the airfoil.
  • FIG. 8 is a partial sectional view of the airfoil of FIG. 7 after further machining and deposition of additional material to rebuild the airfoil
  • FIG. 9 is a view of the airfoil of FIG. 8 after further machining.
  • FIG. 1 shows a fan blade 20 from a gas turbine engine.
  • the blade has an inboard blade root 22 configured for attaching the blade to a disk (not shown).
  • a platform 24 separates the blade root from an airfoil 26 extending from the platform to a tip 28 .
  • the airfoil has a leading edge 30 and a trailing edge 32 with suction and pressure sides 34 and 36 extending therebetween.
  • a midspan damper shroud projection 40 extends from each of the pressure and suction side surfaces.
  • the pressure and suction side projections 40 may respectively interact with the suction and pressure side projections of the adjacent blades to damp blade oscillation.
  • the rotating mass of the midspan shroud projections along with forces from their interaction with adjacent projections subjects the blade to high stresses in areas proximate and inboard of these projections. These stresses may limit repairability of these areas relative to other less-stressed areas.
  • EBPVD electron beam physical vapor deposition
  • the deposited material may have enhanced strength and enhanced adhesion to the base material relative to welding repair techniques. The deposition advantageously occurs in the absence of a transient liquid phase, with solidification directly from the vapor cloud.
  • FIG. 3 shows localized damage such as is associated with foreign object damage (FOD) nicking or chipping the airfoil proximate the leading edge to create a damaged leading portion 30 ′.
  • FIG. 4 shows more general damage such as a leading edge eroded to a location 30 ′′.
  • the damage site is advantageously cleaned of contamination
  • Further removal of base material may provide an advantageous base surface for receiving deposition.
  • the remaining base material of the blade is ground to a preset configuration such as providing an angled leading facet or base surface 50 ( FIG. 5 ).
  • the facet is shown at an included angle ⁇ 1 to the concave pressure side surface 36 .
  • Exemplary ⁇ 1 are over 120°, more narrowly, 120°–130°.
  • the position/orientation of the facet 50 may depend on a number of factors and may be fixed based upon the location of the damage so that, in a given repair facility, any damage at a given point on the airfoil will result in similar machining.
  • a backing scaffold/mask element 52 is secured to the airfoil projecting beyond the facet 50 adjacent to the location of the lost/removed material.
  • the backing element 52 may be a metallic (e.g., aluminum) tape having first and second surfaces 53 and 54 , a trailing portion of the first surface 53 being secured to a remaining intact leading portion of the suction side surface 34 .
  • a forward portion of the surface 53 protrudes beyond the lost leading edge 30 and an intermediate portion extends aligned with a lost portion of the surface 34 along the original contour of the airfoil.
  • the surface 53 may extend fully or partially to either side of alignment with the lost original surface contour.
  • the blade may then be positioned relative to a vapor source 58 emitting vapors along line of sight paths 502 .
  • the source/paths are oriented so that the paths are within slight angles ⁇ 2 and ⁇ 3 off perpendicular to the surfaces 50 and 36 .
  • Exemplary ⁇ 2 and ⁇ 3 are less than 30°.
  • Deposition from the source 58 builds up a first repair material 60 . This is advantageously built up to a surface contour 62 beyond the pressure side portion of the lost original contour of the airfoil. Curvature of the surface 36 produces associated change in ⁇ 3 along the deposition-receiving portion of such surface adjacent the base surface 50 .
  • the blade may be further machined to remove the backing element 52 and create a second facet or base surface 64 extending along the deposited material 60 and the original base material. In the exemplary embodiment, this machining process further removes a previously intact leading portion of the suction side surface 34 .
  • the blade may be reoriented relative to the source 58 so that the surfaces 64 and 34 are just slightly off perpendicular to the paths 502 and a second additional material 66 deposited thereatop to reach a contour 68 beyond the suction side portion of the lost original contour.
  • the deposited materials 60 and 66 may then be machined down to a specified final contour advantageously identical to the lost original contour ( FIG. 9 ). Thereafter, additional surface treatments and/or protective coatings may be applied.
  • the exemplary restoration material is Ti-6Al-4V deposited by an EBPVD or an ion-enhanced EBPVD process.
  • the EBPVD process is believed to provide advantageous physical properties via deposition in the absence of a transient liquid phase. EBPVD is believed to have lower residual stress and better adhesion than other processes such as plasma spray deposition.
  • the exemplary deposition is performed in a vacuum chamber at a pressure between 10 ⁇ 3 and 10 ⁇ 6 torr, more narrowly, approximately 10 ⁇ 4 torr.
  • the exemplary deposition rates are between 10 and 50 micrometers per minute, more narrowly, approximately 20 micrometers per minute.
  • the localized deposition may build up to essentially any depth in one or more stages, the separate stages being characterized by some combination of intervening machining or repositioning of the component relative to the ion source. Individual stages may well deposit material to depths over 2 mm, over 5 mm, or even more. For particularly expensive components, the process could be utilized to completely replace lost features. For example, if a blade is broken off of a unitary disk and blade ring, a replacement blade may be built up from the disk.
  • the same procedure may be used to restore material to the trailing edge of the airfoil or to the leading or trailing edges of the midspan shroud or to tip regions, even where lost material has exceeded traditional repair limits. Similar deposition could effect repairs on the suction or pressure side surfaces more remote from the edges. For such repairs, single deposition stages would typically be sufficient. On a convex surface (e.g., of the suction side), a relatively flat facet machining could be particularly convenient. On a concave surface (e.g., of the pressure side) a concave machining (e.g., with a doubly convex grinding quill) may be appropriate. Advantageously, with such concave machining the machined surface remains within the desired angle of normal to the vapor paths along its entire area.
  • Machining other than the flat-facet grinding may be utilized.
  • the most important element of effective machining is providing a clean base surface for subsequent deposition.
  • a desired or acceptable level of roughness may be provided.
  • the blade remains stationary during each deposition stage so as to limit the presence of columnar discontinuities in the deposited material.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Engineering & Computer Science (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Physical Vapour Deposition (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Furnace Housings, Linings, Walls, And Ceilings (AREA)
  • Arc Welding In General (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
US10/635,694 2003-03-03 2003-08-05 Method for turbine element repairing Expired - Lifetime US7216428B2 (en)

Priority Applications (18)

Application Number Priority Date Filing Date Title
US10/635,694 US7216428B2 (en) 2003-03-03 2003-08-05 Method for turbine element repairing
US10/734,696 US7509734B2 (en) 2003-03-03 2003-12-12 Repairing turbine element
UA20040705668A UA79258C2 (en) 2003-08-05 2004-07-12 Method for repair of turbine element made of titanium alloy
UA20040705667A UA81401C2 (en) 2003-08-05 2004-07-12 Method for renewal of turbine part, appliance for material deposition on part (variants) and renewed metal part
KR1020040054709A KR100704806B1 (ko) 2003-08-05 2004-07-14 터빈 요소 수리
KR1020040054708A KR100704805B1 (ko) 2003-08-05 2004-07-14 터빈 요소 수리
SG200404327A SG108982A1 (en) 2003-08-05 2004-07-15 Turbine element repair
SG200404374A SG109003A1 (en) 2003-08-05 2004-07-22 Turbine element repair
CNA2004100560279A CN1584103A (zh) 2003-08-05 2004-08-05 涡轮零件的修复
JP2004229403A JP4160027B2 (ja) 2003-08-05 2004-08-05 タービン部材の修理方法および材料堆積装置
JP2004229402A JP4021883B2 (ja) 2003-08-05 2004-08-05 タービン部材の修理方法
AT04254725T ATE410530T1 (de) 2003-08-05 2004-08-05 Reparatur von turbinenbauteilen
DE602004016922T DE602004016922D1 (de) 2003-08-05 2004-08-05 Reparatur von Turbinenbauteilen
EP04254725A EP1505168B1 (en) 2003-08-05 2004-08-05 Turbine element repair
EP20040254727 EP1505169B1 (en) 2003-08-05 2004-08-05 Ion plating method and apparatus.
CNA2004100560387A CN1584104A (zh) 2003-08-05 2004-08-05 涡轮机元件的修理
US11/930,564 US20080057254A1 (en) 2003-03-03 2007-10-31 Turbine element repair
US12/756,624 US20100196684A1 (en) 2003-03-03 2010-04-08 Turbine Element Repair

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US20070079507A1 (en) * 2005-10-12 2007-04-12 Kenny Cheng Blade shroud repair
US20080236536A1 (en) * 2007-03-30 2008-10-02 Caterpillar Inc. Cast engine component having metallurgically bonded inserts
US20090068349A1 (en) * 2007-09-12 2009-03-12 Mccall Thomas Method of repairing a turbine engine component
US20090104003A1 (en) * 2007-10-18 2009-04-23 United Technologies Corp. Gas Turbine Engines Systems and Related Methods Involving Dimensionally Restored Fasteners
US8020295B2 (en) 2007-10-18 2011-09-20 United Technologies Corp. Methods for dimensionally restoring a fastener for a gas turbine engine
US20100098896A1 (en) * 2008-10-16 2010-04-22 Edward Claude Rice Patch
US20100095684A1 (en) * 2008-10-16 2010-04-22 Edward Claude Rice Morphable composite structure
US20100096183A1 (en) * 2008-10-16 2010-04-22 Edward Claude Rice Tape
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US9249491B2 (en) 2010-11-10 2016-02-02 General Electric Company Components with re-entrant shaped cooling channels and methods of manufacture
US8741420B2 (en) 2010-11-10 2014-06-03 General Electric Company Component and methods of fabricating and coating a component
US8753071B2 (en) 2010-12-22 2014-06-17 General Electric Company Cooling channel systems for high-temperature components covered by coatings, and related processes
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US8910379B2 (en) 2011-04-27 2014-12-16 General Electric Company Wireless component and methods of fabricating a coated component using multiple types of fillers
US8506836B2 (en) 2011-09-16 2013-08-13 Honeywell International Inc. Methods for manufacturing components from articles formed by additive-manufacturing processes
US9039917B2 (en) 2011-09-16 2015-05-26 Honeywell International Inc. Methods for manufacturing components from articles formed by additive-manufacturing processes
US9249672B2 (en) 2011-09-23 2016-02-02 General Electric Company Components with cooling channels and methods of manufacture
US10005160B2 (en) 2011-10-06 2018-06-26 General Electric Company Repair methods for cooled components
US9249670B2 (en) 2011-12-15 2016-02-02 General Electric Company Components with microchannel cooling
US9266170B2 (en) 2012-01-27 2016-02-23 Honeywell International Inc. Multi-material turbine components
US9598963B2 (en) 2012-04-17 2017-03-21 General Electric Company Components with microchannel cooling
US9243503B2 (en) 2012-05-23 2016-01-26 General Electric Company Components with microchannel cooled platforms and fillets and methods of manufacture
US9120151B2 (en) 2012-08-01 2015-09-01 Honeywell International Inc. Methods for manufacturing titanium aluminide components from articles formed by consolidation processes
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US10927684B2 (en) 2016-02-08 2021-02-23 Raytheon Technologies Corporation Repairing a coating with a pre-configured coating patch

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ATE410530T1 (de) 2008-10-15
US20040172825A1 (en) 2004-09-09
KR100704805B1 (ko) 2007-04-10
EP1505168B1 (en) 2008-10-08
SG109003A1 (en) 2005-02-28
JP4021883B2 (ja) 2007-12-12
DE602004016922D1 (de) 2008-11-20
EP1505168A3 (en) 2006-06-14
KR20050016002A (ko) 2005-02-21
JP2005054801A (ja) 2005-03-03
UA81401C2 (en) 2008-01-10
EP1505168A2 (en) 2005-02-09
UA79258C2 (en) 2007-06-11

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